Note: Descriptions are shown in the official language in which they were submitted.
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TITLE: LEAK RESISTANT NOZZLE BALL FOR USE IN SPRAY
NOZZLES AND FLUID CONNECTION DEVICES
FIELD OF THE INVENTION
This invention relates to fluid connections provided by a ball and
socket joint. This invention is more particularly concerned with the
sealing of such a joint.
The invention will be described with particular reference to use
with spray nozzles, but is not limited to such applications and has
general applicability to any such fluid connection.
BACKGROUND OF THE INVENTION
Spray nozzles are utilized in many areas where a spray of liquid is
required: metal washing, foam control, asphalt spraying, vehicle
washing, and dishwashers, to name but a few. In metal washing, a
popular form of spray nozzles is the adjustable ball clip-on spray nozzle.
The nozzle may be mounted on a tubular header which has been drilled
to provide a communicating hole. The nozzle comprises a body with a
hemispherical socket for accommodating a nozzle ball and a nozzle ball,
which is retained in the socket by a collar which engages external screw
thread on the body. The body is provided with a spigot for extending into
the header hole. A passageway extends through body to a chamber which
is between the socket and the nozzle ball. The chamber is in flow
communication with a central cavity in the nozzle ball and the cavity
extends to a nozzle spray outlet.
In use, fluids such as water, paint, or other coating materials are
forced through the header, through the spigot, through the passageway,
through the chamber, through the cavity of the nozzle ball, and out the
nozzle spray outlet. T'he fluid may be at high pressure.
It is to be appreciated that this ball and socket is applicable to any
fluid conduit, and has the great advantage that it is infinitely adjustable
through a wide range of angles.
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Tightening the collar is intended to press the nozzle ball against
the body sufficiently to prevent leakage. Complementary sizing and
shaping of socket and the nozzle ball allow the direction of spray to be
adjusted by rotating the nozzle ball. To allow the nozzle ball to be
adjusted, the seal between the socket and the nozzle ball cannot be made
by means of, for example, an adhesive or caulking compound. Hence, to
prevent leakage between the ball and the socket, both parts should ideally
be made to very close dimensional tolerances. If the components are
machined from metal, reasonably tight tolerances can be obtained, and
suitable metals or other materials are strong enough to maintain their
dimensions under pressure. However, machining the components from
metal is very costly. Alternatively, if the assembly is made of a rigid
material, a separate gasket, packing or seal may be used, but such a seal
would necessarily restrict the adjustment of the nozzle ball.
Plastic is the preferred material because of the economy of
injection moulding the components. However, if the nozzle ball and the
body are made of injection moulded plastic, the close tolerances on
sphericity and diameter of the nozzle ball and socket cannot be
maintained because of the uneven cooling of the parts and subsequent
non-uniform shrinkage during moulding. Shrinkage is related to wall
thickness, moulding pressure and cooling rate. Many plastics typically
shrink by the order of 7%, with thicker parts shrinking the most.
Consequently, the dimensions of the plastic components vary from piece
to piece, causing an imperfect fit, and leakage between the nozzle ball and
the nozzle body.
If the components are sufficiently rigid, a separate gasket, packing
or seal can be used, but this has disadvantages. It may limit the angle of
movement of the nozzle ball. If the ball is moved too far, a lip, between
the outside of the ball and an internal bore, can snag such a seal and
damage it. Such a gasket or the like adds to the complexity and cost.
Leakage problems are worsened when the nozzle spray is used at
relatively high pressures. The high pressure of fluid from the header
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may force the fluid into interstices between the nozzle ball surface and
the socket further deforming the assembly.
Leakage between the nozzle ball and the socket results in a loss of
pressure and a loss of fluids which would otherwise be directed through
the spray outlet. In addition, where fluids being are used, such as paint
or phosphates which solidify in use, fluids can accumulate between the
nozzle ball and the socket may result in an adhesion between the nozzle
ball and socket, thus preventing the redirection of the spray outlet.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a
nozzle ball for use in a spray nozzle, the nozzle ball comprising: a main
body having a substantially spherical surface; a spray outlet in the nozzle
ball; an inlet aperture in the nozzle ball; a cavity in the nozzle ball
providing flow communication between the inlet aperture and the spray
outlet; and a sealing lip on the main body, the sealing lip extending
around the inlet aperture and extending radially outwardly beyond the
spherical surface, whereby in use, when mounted in a socket having a
spherical surface complementary to the spherical surface of the main
body, the sealing lip can be pressed against the spherical surface of the
socket to form a seal.
It will be understood that the term "substantially spherical" as
used in this disclosure means sufficiently spherical to permit rotation of
the nozzle ball and enable an adequate seal to be formed between the
nozzle ball and the socket.
The sealing lip extends radially outwards away from the center of
the spherical surface. It can take many forms. Preferably, the nozzle ball
includes an axis, extending through the center of the spherical surface of
the main body, with the spray outlet and the aperture co-axial with the
axis and the sealing lip including a circular sealing edge coaxial with the
axis. More preferably, the sealing lip includes an outer surface, e.g. a
conical surface, tangential with the spherical surface of the nozzle ball, so
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as to minimise the number of edges that can become caught as the nozzle
is adjusted. The sealing lip may also comprise a simple annular
projection.
In accordance with another aspect of the present invention, there
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is provided a spray nozzle assembly comprising:
a nozzle ball which comprises a main body having a substantially
spherical surface, a spray outlet in the nozzle ball, an inlet aperture in the
main body, a cavity in the nozzle ball providing flow communication
between the inlet aperture and the spray outlet, and a sealing lip on the
main body, the sealing lip extending around the aperture and extending
radially outwardly beyond the spherical surface;
a nozzle body defining a part-spherical socket, which is open at one
end of the nozzle body, and a passageway extending from the socket to
the other end of the nozzle body, the socket including a part-spherical
surface complementary to the spherical surface of the nozzle ball,
wherein the nozzle body includes a first coupling formation; and
locking means including a second coupling formation, adapted to
engage the first coupling formation, so as to secure the nozzle ball within
the socket and to press the nozzle ball into the nozzle socket, whereby the
sealing lip of the nozzle ball is pressed against the socket to form a seal.
The nozzle ball of this aspect of the invention can include all the
features of the nozzle ball outlined above. The present invention is
particularly applicable to nozzle assemblies formed from plastic, as most
plastics suffer from significant shrinkage during moulding, making it
difficult to maintain the tight tolerances necessary for forming a seal in
conventional designs.
Accordingly, the nozzle ball, the nozzle body and the locking
means can be integrally moulded from a plastic material. The nozzle ball,
the nozzle body and the locking means are preferably integrally moulded
from glass reinforced polypropylene.
A further aspect of the present invention is based on the
realization that the invention has general applicability to forming a
connection between any two fluid conduits where it is necessary to form
a good seal and to permit any desired angle to be provided between the
two conduits. This aspect of the invention provides a fluid connection
device, for providing fluid communication between two fluid conduits,
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the device comprising:
a first member defining a socket open at one end of the fluid
member, and a connection port extending from the socket and open at
the other end of the fluid member, the socket defining a part-spherical
surface;
a second fluid member including a main body having a spherical
outer surface complementary to the spherical surface of the socket, an
aperture in the socket, a second communication port and a cavity within
the second member extending between the second communication port
and the aperture, and a sealing lip around the aperture and extending
radially outwardly beyond the spherical surface of the second fluid
member; and
engagement means, engagable with the first fluid member, for
maintaining the second fluid member within the socket and for pressing
the sealing lip of the second fluid member against the socket to form a
seal. Again all the other variations of the other aspects of the invention
are applicable to this aspect of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present invention and to show
more clearly how it may be carried into effect, reference will now be
made, by way of example to the accompanying drawings which show a
preferred embodiment of the present invention and in which:
Figure 1 is a perspective view of an adjustable ball spray nozzle
mounted on a cylindrical header in accordance with the present
invention;
Figure 2 is a sectional view corresponding to a view along line 3-3
of Figure 1 and showing a prior art sealing ring; and
Figure 3 is a partial sectional view along line 3-3 of Figure 1 and
showing details of the nozzle ball of the spray nozzle of present
invention.
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DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference is first made to Figure 1 of the drawings, which is a
perspective view of an adjustable ball spray nozzle 10 mounted on a
cylindrical pipe header 12. This form of nozzle will be used as an
exemplary application for the ball spray nozzle of the present invention
and therefore a detailed description of the nozzle ball of the invention
will be preceded by brief description of a typical nozzle 10.
As shown in Figure 2, a nozzle 10 comprises a body 14 having a
through-passage 38 in communication with the interior of the header 12
and a nozzle ball 16, rotatably mounted on the body 14 and retained on
the body 14 by a collar 18 which engages an external screw thread on the
body 14. The body 14 has a base portion 19 which defines a saddle-like
shape conforming to the external surface of the header. The components
of the nozzle 10 are formed of a suitable material such as plastic, stainless
steel or other rigid material. A particularly suitable material is glass-
reinforced polypropylene.
A spring clip 20 is pivotally mounted on the body 14 for releasably
retaining nozzle 10 on header 12. Clip 20 is formed of a length of spring
wire having two inwardly directed ends 21 (only one visible in Figure 1)
which engage recesses 23 on body 14, a part circular header engaging
portion 24 and an outwardly directed portion 26 which an operator may
use to release clip 20 from header 12. The header engaging portion
extends through slightly more than a semicircle, so as to provide an over
center type action, to secure the nozzle in position.
Referring now to Figure 2 of the drawings, which shows a cross
section of the spray nozzle, a spigot 30 extends from body 14 of nozzle 10
into a bore 32 provided in header 12. Surrounding the spigot 30 is a
groove 34 for receiving a sealing member. The sealing member is in the
form of an O-ring 46. The passageway 38 extends through the spigot 30
and into a chamber 40. The chamber 40 is defined by the space between a
substantially hemispherical socket 41 and the nozzle ball 16. This nozzle
ball 16 is intended to be of complementary shape to socket 41 and
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rotatable therein and is provided with a cavity 42 (Figure 3) for flow
communication with the chamber 40 throughout the range of
movement possible for nozzle ball 16. A nozzle spray outlet 43 is in flow
communication with the cavity 42. The spray outlet 43 is formed in a
cylindrical post 44 which extends from and is integral with the nozzle
ball 16, outwards through collar 18. The spray outlet 43 is provided with
a particular configuration, depending on the form of spray required.
The socket 41 is generally spherical and comprises a bottom part
that is a hemisphere. This continues into a top part defined by a series of
fingers 45 separated by suitable gaps (not shown). These fingers 45 serve
three major functions. Firstly, they are resilient enough, to spread apart
to permit the ball 16 to be inserted. Secondly, in use, they prevent direct
contact between the collar 18 and the ball 16, so that, as the collar 18 is
tightened, a preset position for a ball 16 is not disturbed. Thirdly, they
deflect inwards, to enable the collar 18 to apply an axial load to the ball 16
pressing it downwards, as shown in the Figures, with the intention of
sealing the ball to the socket 41.
In use, the nozzle 10 is subject to a pressure from a pressurized
fluid from the header. With significant pressure, it has been found that
the forces acting on the nozzle may be such that integrity of the seal
between nozzle ball 16 and socket 41 is affected, leading to leakage of fluid
between nozzle ball 16 and socket 41. Additionally, as noted above, poor
tolerances in manufacture may make it difficult to achieve a satisfactory
seal. Here, at least part of the problem is that the inherent rounded shape
of the ball and socket distribute any axial load over a large area; i.e. there
is no distinct sealing surface which is subject to a high sealing pressure to
form an adequate seal.
Figure 3 of the drawings illustrate a nozzle ball 16 in accordance
with the preferred embodiment of the present invention. Like
conventional nozzle balls, the nozzle ball 16 comprises a main body
having a substantially spherical surface 52, a cylindrical post 44, a spray
outlet 43, a cavity 42, and an aperture 36. However, in accordance with
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the present invention the ball 16 is provided with a lip 50. The cavity 42
is in flow communication with an inlet aperture 36 and with the spray
outlet 43.
The lip 50 comprises an outer surface 56 and an inner surface 58,
and chamfered end surface 54. The inner surface 58 defines part of the
cavity 42, and the outer surface 56 is conical and tangential to the
spherical surface 52. Hence, the lip 50 forms a cone-like structure around
and coaxial with the aperture 36. The lip 50 need not be perfectly conical
and can comprise other profiles. The lip 50 encircles the aperture 36. The
chamfered end surface 54 has a sealing edge 55, where it joins the outer
surface 56.
In this embodiment, the conical outer surface has a cone
generating angle indicated at E. The angular extent of the surface 56 is
indicated by the angle F. The external and internal diameters of the outer
surface 56, as measured in planes perpendicular to the axis of the nozzle
ball 16 are indicated at A and B. The inlet aperture 36, adjacent the lip 50
has a diameter indicated at C. It will be appreciated that the radial
difference between the diameters B and C is equal to the width of the
chamfered end surface 54. The main diameter of the ball 16, throughout
center 48 is indicated at D.
In view of the fact that the conical outer surface 56 is tangential to
the main cylindrical portion of the ball 16, the sealing edge 55 is located
on a radius R which is greater than the radius of the ball 16 itself. This is
such that this edge 55 will form a tight seal with a socket, as detailed
below.
Thus, what is essential to the invention is the provision of a
sealing edge 55, or surface, which projects radially outwardly from the
ball 16 and presents a sufficiently small surface area that sufficient
pressure can be generated between it and a socket, to form a seal. Thus,
instead of an edge, an annular surface with some measurable width
could be provided. It will also be realised that the conical profile of the
surface 56 is not essential. Thus the ball 16 could be wholly conventional
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except for a raised annular lip around the aperture 36, the lip extending
either parallel to the main axis of the ball 16, or radially outwardly from
its center 48. As depicted in Figure 3, the edge 55 is preferably a sharp
edge.
While the nozzle ball preferably has a cylindrical post 44, as
depicted in Figure 1 and 2, this is not essential to the invention, as
described.
In use, when the ball 16 is pressed into socket 41 by screwing down
of collar 18, the edge 55 of lip 50 deforms and also generates a relatively
high local stress forming a tight seal with socket 41. Either one or both of
the lip 50 and the nozzle body 14 are sufficiently resilient to deform
sufficiently to form a good seal. This resiliency also ensures that, even if
the ball 16 is not a perfect fit with socket 41 when unloaded, a good seal
can still be formed. Thus, as the collar 18 is tightened on the thread, it
imposes a force on ball 16, pushing ball 16, including lip 50, against socket
41. This forms a tight, leak resistant seal. As seen in Figure 2, it is
preferred that the entire lip 50 is in contact with the socket 41, for all
angles of the ball 16.
The socket 41 is preferably more resistant to deformation than the
lip 50. At least when all component are formed from the same material,
e.g. glass-filled polypropylene, the socket 41 will inherently be more
resilient to deformation, due to the different wall thicknesses. Hence, the
lip 50 is deformed inward when force is applied to the ball 16, as described
above. As the socket 41 is substantially hemispherical, this causes the lip
50 to assume a less conical and more spherical shape, complementary to
the socket 41. To adjust the position of the ball 16, the fingers 45 are
sufficiently resilient, to enable the nozzle 16 to be adjusted easily.
For sealing to occur at high fluid pressures, the socket 41 is
substantially less flexible than the lip 50, as above. Thus, at high fluid
pressures the hoop stress on the inner surface 58 causes the thin end of
the conical section of the ball to expand to further conform to the socket
41, thereby sealing even more tightly.
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Thus it can be seen that the nozzle described above provides an
effective seal between the nozzle ball 16 and the socket 41. Furthermore,
when used under high pressure, the force applied to the inner surface 58
by the fluids presses lip 50 further tightly against the socket 41, thus
increasing the effectiveness of the seal. At the same time, the use of the
present invention, does not significantly restrict the ability to redirect the
spray from the spray outlet 43 by rotation of the ball 16.
In this particular example, the various dimensions of a suitable
nozzle ball 16 are set out below and correspond to the dimensions: A, the
diameter of nozzle ball 16 at the point at which the tangent line defining
the outer surface 56 meets the spherical surface 52; B, the diameter of the
nozzle ball 16 at edge 55; C, the diameter of the aperture 36; and D, the
diameter of the nozzle ball 16 at the spherical surface 52. The various
dimensions are as follows:
A= 0.9751"
B= 0.805"
C= 0.770"
D= 1.126"
E= 30°
F= 16.85°
It will be understood that no limitation of the scope of the
invention is hereby intended. While the inventions is being disclosed
and described with references to a limited number of embodiments,
those skilled in the art will appreciate that the various modifications,
variations and additions to the nozzle may be made, and is therefore
intended in the following claims to cover each such variation, addition
and modification as falls within the true spirit and scope of the
invention. Such alteration and further modifications in the illustrated
device, in such applications of the principles of the invention as is
illustrated herein as with normally occurred to one skilled in the art to
which the inventions relates are considered as included in the
invention.
